Coil winding machine



Non 28, 1950 w. H. sHELEY `2,5?L534 I COIL WINDING MACHINE Filed Jan. 21, 1949 12 Sheets-Sheet 1 /26 IWW/44 /zf 2W/W WAYNE HAAMAN wmv HIS ATTOB NEY Nov. 28, 1950 w. H. sHELEY 2,53L534 con. WINDING MACHINE Filed Jan. 21, 1949 1-2 sheets-sheet z l N VE N TOF) WAYNE HARMAN 'SHEUY Y 5m A Mm/ 15% HIS AWMNEYS Nov. 28, 1950 w. H. sHELEY COIL WINDING MACHINE 12 Sheets-Sheet 3 Filed Jan. 21, 1949 :NvfNroA WAYNE HARMAN muy ,MW/MMM Za HIS ATTORNEYS Nov. 28, 1950 w. H. SHI-:LEY

con. WINDING MACHINE 12 Sheets-Sheet 4 Filed Jan. 2l, 1949 NVENTDB WAYNE HARMAN SHELEY BVM/@WAHM v 7441/ HIS A TTOHNEYS Nov. 28, 1950 x Filed Jan. 2l. 1949 W. H. SHELEY COIL WINDING MACHINE 12 Sheets-Sheet 5 INVENTOH WAYNE HARMAN SHH Y Nqv. 21s, 195o Filed Jan'. 21, 1949 Y w. H. sHELEY 2,531,534

con. WINDING MACHINE 12 Sheets-Sheet 6 IN VEN 70H WAYNE HARMAN .HELVr HIS ATTOHNE l5 Ngv. 28, v1950 w. H. SHELBY l 2,531,534

l con. WINDING MACHINE .Filed Jan. 21. 1949 A Y 12 sheets-sheet 7 NLENTB WAYNE HAHMN HELEY B'YMMMU M HIS ATTONEYS Nov. 28, 1950 w. HsHELEY con. wINDING MACHINE:

12 Sheets-Sheet 8 Filed Jan. 21, 1949 Y l 2 5., H Y oN TA LH .WR WFM mw MM Y nu Hi ,ATTOBNEY NUN- 28 M95@ w. H. SHELEY coIL WINDING MACHINE 12 Sheets-Sheet 9 Filed Jan. 2l, 1949 NM Wn.. wm :L E Y B 0V. 28, 1950 w, H, SHELEY 2,531,534

COIL WNDING MACHINE Filed Jan. 21, 1949 12 sheets-sheet 1o IN VEN TOR WYNE HARMAN SHELEY NOV. 2S, 195@ W, H, SHE-:LEY 2,531,534

COIL WNDING MACHINE Y Filed Jan. 2l, 1949 l2 SheeS-Shee't ll INVENTOH V HIS ATTORNEYS Nov. 28,1950 v w. HSHELEY Y 2,531,534

coIL WIINDING MACHINE I H15 ATTORNEYS Patented Nov. 28, 1950 UNITED STATES TENT OFFICE con WINDING MACHINE Application January 21, 1949, serial No. 71,972

7 Claims. l

This invention relates to machines for winding electrical coils, for example, inter-pole coils used on dynamo electric machines.

An object oi the invention is to provide a machine for winding edgewise a flat strip, the width of which is considerably greater than the thickness, around an oblong form which is rounded at its edges. During winding, the form is oscillated and rotated while the bar stock is confined in a manner such as to prevent buckling.

Further objects and advantages of the present invention will be apparent from the followingr description, reference being had to the accompanying drawings, wherein a preferred embodiment of the present invention is clearly shown.

In the drawings:

Fig. 1 is a side view of the machine as viewed in the direction of arrow I of Fig. 2. y

Fig. 2 is in part a sectional view and in part a side view on lineVZ-Z of Fig. 1.

Fig. 3 is a sectional view on line 3--3 of Fig. 2.

Fig. 4 is a sectional view on line 4--4 of Fig. 3.

Fig. 5 is a sectional view on line 5- 5 of Fig. l.

Fig, 6 is a sectional view on line 6-6 of Fig. 2.

Figs. '7, 8, 9 and 10 are sectional views taken, respectively, on lines 1'I, 6 8, 9 9 and lil-I6 of Fig. l5.

Fig. 11 is a sectional .view on line iI-I I of Fig. 6.

Figs. 12 and 13 are sectional views taken, respectively, 'on lines I2-I2 and I3-I3 of Fig. 5.

Fig. 14 is a sectional view on line I-It of Fig. 6.

Fig. 15 is a fragmentary view looking in the direction oi arrow I5 of Fig. 3.

Figs. 16-21 are diagrams illustrating the operation of the machine.

Referring to Fig. 1, a base plate I@ which is supported upon a oor in any suitable manner is attached to four rods I I into which four rods I2 are screwed, a plate I3 being clamped between shoulders provided by rods II and l2. Rods I2 support a plate I4 supporting a cylinder I5 containing a piston from which a 4rod i6 extends. Rod I is connected by a clevis Il, a link IS and a clevis I9 with a plate 2E) attached to sleeves 2I which slide on two of the rods I2 thereby guiding the plate 26 for vertical movement. There is shown also in Fig. 5 plate I3 which supports a gear case comprising a bottom plate 22, a cylindrical member 23 and .a cover plate 2t having a central opening 25. Plate 24 supportsva plate26 having a centralopening 21. A space between plate 2li and plate 26 is occupied by a lplate 28 l2 which is free to slide between plates 24 and 26 and which at all times closes the opening 25.

Beier-ring to Fig'. 6, plate I3 supports a stud 30 which provides a guide for a plate 3i movable linearly and rotatively upon the plate 22, said plate 3i having an elongated hole 32 for this purpose. The head 35a of stud 32 retains plate si upon p1ate22.r

Referring to Fig. ll, an oblong gear OG, which comprises semi-circular segments 33 and rack segments 35, is located upon plate 3I by dowel pins 35 and is attached thereto by screws 36. Gear 0G provides an oblong opening 37 which receives the head 36a of stud 36, Screws 39 .(Fig. 5) nSecure to the gear support 4U for a Winder form 1li. The axes of segments 33 coincide with axes A and `13 (Fig. 16), respectively, of the cylindrical end portions of form 4I. Support 40 extends into an oblong hole in a plate 42 which is urged upwardly against plate 24 (Fig. 6) by springs 413. Screws 44 secure to plate 42 a block TG5. which extends through an oblong opening in plate 28 and which is provided with an oblong opening receiving the form 4I A block 46 (Figs. 5 and '7) is attached to block 45 and both these blocks provide aligned grooves 45a and 46a for receiving the bar or flat wire to be formed into a coil. The start end of the at wire is provided with a hook bent downwardly to be received .by .a groove 46h in block 46. The ilat wire is guided to the form by a groove 50 (Fig. 7) in the top surface of a bracket 5| which is shown in Fig. Zas attached to plate I3. The wire is maintained in groove 50 by a plate 52 (Fig. 5) urged downwardly by a spring 53 surrounding a screw 54, the lower end of which is threaded into plate .52 .and the upper end of which is guided by a bushing 55 screwed into the plate 20. Upward movement of left end of the plate 52 is restricted by a stop screw 56. Because the wire is conned in a groove, movement of gear OG is restricted to linear movement except when either one of its semi-circular segments 33 is engaged by a driving rpinion (Fig. 16) to be described more fully hereinafter.

Asthe wire is fed into the machine by operation thereof it passes between oil soaked felt strips .58 and 59 attached respectively to a lever @El and -a .plate @Lattached to bracket 5I. Lever 66,(1Fig. 13) ispvoted at 66a on plate 6I and has a wire receiving groove 53D. Plate 6I supports an oil containing vessel 52 into which felt strip 59 extends.

The wire `is cut after the winding operation by a blade .65 (Fig. 5) which cooperates with a shearing edge providing a wall of a blade receiving aperture 65 provided by bracket 5|. As the Wire is cut by the left edge of the blade 55, its right surface 65a bends the wire about the edge 66a. adjacent the hole 63 to form a hook at the end of the wire. Blade 65 (Fig. l) is connected by link 61 with a lever |33 pivotally supported by bracket 59 and urged upwardly by spring 10.

Referring to Fig. 6, plate 20 carries taper roller bearings 12 and 13 which support a shaft 14, the lower end of which touches the block l5 when plate E5 is in the position shown in Fig. 6. Shaft l has a flange which engages the upper end of form (5|. Axial movement of shaft 14 is limited by a disc l@ which a screw 11 attaches to the shaft. late 2i! carries a wear plate 18, the lower surface of which is flush 'with the lower surface of the ilange 15. plate a clamp 5d which retains a plate 8| (shown in Fig. le) which is located by pins 82. Plate 8| is shaped to provide clearance for the lower end of the shaftW 14, and its thickness is substantially that of the thickness of the Wire which is received between the form 4| and the edge Sla of plate 8|.

The wire, while being wound around the form 4| is coniined between an upper relatively fixed member, which includes disc 15 and wear plate i8, both engaging the top surface of form 4| when frame ly movable member provided by block 45. Block directly engages the wire of the rst turn and springs 43 operate to cause the block to urge the iirst turn and succeeding turns upwardly toward the disc 15 and the wear plate 18. The lower end of shaft i@ provides a smaller disc which, in conjunction with surface Bia (Fig. 16) of plate 8|, provides means for causing the wire to conform to the cylindrical portion of the form 3| as it is rotated.

Referring to Fig. 6, the parts enclosed within the gear case are lubricated by oil introduced through an aperture 83 closed by a plug 8d. This oil may be drained through an aperture 85 normally closed by a plug 25. The gear case contains a bracket 5|) located by dowel pins 5i relative te plate 2i. and secured to plate |3 by screws 92 (Fig. 9). A block 53 occupies the space between one side of bracket 95 and the wall 23 to transmit side pressure. The gear OG meshes with a gear keyed to a shaft 56 which is journaled in ball bearings 91 and 95 supported respectively by bracket 95 and plate I3. For more quiet operation, these meshing gears have helical teeth.

Referring to Fig. 2, shaft 55 is journaled also in bearing 9E supported by a bracket |83 supported by a bracket |5i supporting bearings |52 for a shaft |53. Shafts and |53 are connected by bevel gears E34 and m5 attached respectively to these shafts. Shaft |53 is connected with a driven member of a clutch |||l, the driving member of which is connected by a coupling with a power driven shaft H2. The connection between the driven members of the clutch is controlled by a disc H5 which, in response to arresting its motion, effects disengagement of the clutch and which, in response to its release, effects engagement of the clutch. A well known clutch of this type is the Hilliard clutch.

As shown in Fig. 4, disc H5 is notched to provide a surface H5 engageable with a stop pluger ||1 guided by lever H3 pivoted at ||9 on a bracket |25 attached to base plate I5. A spring is down, and a lower or relative- I Screws 13 secure to |2| urges the plunger upwardly and its upward movement is limited by plate |22 attached to lever H8 by a screw |23. Lever ||8 is urged clockwise (Fig. 4) by a, spring |25 so that the lever tends to ride on the disc ||5 which rotates counterclockwise so that it is ready to stop motion of the disc ||5 by engagement of plunger H1 with the surface ||6 of the disc. Counterclockwise motion of lever ||8 is effected by a pedal |25 pivoted at |23 on a bracket |21 attached to plate and urged upwardly by a spring |28 surrounding a, rod |29 passing through a hole |35 in plate lil and a hole |3| in pedal |25. A nut |32 threaded on rod |29 retains a washer |33 which retains the pedal |25. The spring E28 is confined between a washer |34 supported by plate lil and a washer |35 retained by head |35 of rod |29. Lever H8 is connected by a pin |43 with a clevis 15| connected with a rod |42 which passes through a hole |53 in pedal |25 and is engaged by nut |44 which retains a washer |45. When pedal |25 is moved downwardly, motion is transmitted by rod |42 of lever H8 to cause it to move counterclockwise so that disc i5 is released and the clutch engages.

The lever IIB is controlled also by a timing mechanism which comprises a sprocket |55 (Figs. 2 and 3) attached to shaft S5 and connected by chain |5| with a sprocket |52 and engaging an idle sprocket |53 journaled on the screw |54 carried by bracket |55 which, as shown in Fig. l5, is supported by screw studs |55 and |51 attached to plate I3. Bracket |55 pivots about stud |51 in order to position the sprocket |53 to tighten the sprocket chain |5|. The bracket is retained in adjusted position by tightening the nut |58 on the stud which passes through an arcuate slot ide of bracket |55, said slot having its geometrical center at stud |51. The tightening of nut |58 clamps the bracket |55 against a spacer |68 which in turn is clamped against the plate I3.

Sprocket |52 is attached to a shaft |62 which, as shown in Fig. l, is journaled in bearing members |53 and |54 attached, respectively, to plates l5 and I. Sprocket |52 drives a worm |55 meshing with a worm gear |66 which, as shown in Fig. 3, is attached to a shaft |61 journaled in bearings provided by brackets |59 and |69 attached to plate l. Shaft |31 is connected with a disc |15 (Fig. 4) having arcuate slots |1| each for receiving a screw |12 threaded into a cam |13 thus providing for adjustment of the cam |13 relative to shaft |61. The direction of rotation of the cam |13 is clockwise in Fig. 4. Cam |13 provides a high land or dwell |13a, a slope |13b, a low land and a slope |13d. Cam |13 is engaged by a roller |16 supported by a lever |15 pivoted on a screw |16 attached to bracket |59 and connected by link |11 with lever l I8. When roller |14 engages low land |13c, lever ||8 is permitted to move by spring |24 into contact with disc H5 in preparation for arresting movement of said disc. When roller |14'. engages high land |1311, the plunger |1 is retracted from the disc.

Preparatory to winding a coil from a new supply of wire, the plate 20 is lowered to the point shown in Fig. 5, and the wire is passed through the groove 5l? and a little past the opening 66 (Fig. 5). The blade G5 is manually lowered so as to shear the wire, remove the excess and to cause the edge portion thereof to be bent down around the corner 66a to form a hooked end portion. The plate 2u is raised by admitting pressure uid to the lower end of the cylinder l5 to permit by manual operation the pulling of the wifi-e throughthe groove 5!! to the left (Fig. 7) and the placing of the hooked end of the wire th loth @6h "0f bl'ii 4.5. Theil plate I2i] iS lowered to the position shown in Fig. '5 b'y admitting pressure -fluid to the upper end of cylinder l5. Pedal |25 (Fig. a) is depressed for a time suicient 'to cause engagement of slope 'lsd and apart of high land li'a oi cam H3 with roller Iii, thereby eiiecting retractionl of plunger l Il and release of disc' H5 x'and 'the trai-isniission of power to shaft 1&3 by clutch I l. Then the pedal E25 is released and c'oil winding proceeds for atime suffi'eient to complete the winding of the` Coil and when the c'l iS Wound the 'Slope II T31) Willhave passed the roller] T4 to allow it to move upon the low land Hic so that the stop plunger Ill is ready to receive the surface l I6 of disc H5 to arrest movement thereof so that operation o f the machine ceases.

Fig. i6 represents the condition of the machine when winding starts. As gear 95 rotates counterclockwise, gear OG moves successively into the positions shown in Figs. 16 through 2i to cause a co'il o'f wire to be formed. As the wire is bent edgewise, it is caused to conform to the forin il by virtue of the lower end of the shaft it and the surface Sia of plate 8L In order to show clearly the different positions of the frm iii, the geometrical centers of the 'cylindrical 'end 'surfaces are marked Aiad B respectively. Fig. 21 shows that one turn of the wire has been wound following the position of gear OG shown Fig. 2-1 which moves to the position shown in Fig. r16 and the-cycle is repeated. Each time gear OG operates through one cycle, that is, from Figs. 16 to 21 and back to Fig. 16 position, the shaft |03 (Fig. 2) makes two revolutions and cam |73 turns 1/10 of a revolution, this ratio of movement being that required for aV particular coil which, for example, is to have 91/2 turns. Therefore, the machine is stopped automatically when the winding mechanism is in the position shown in Fig. 19 which is the position it has at the end of the iirst half turn and obviously at the end of the 91/2 turns. In this position of the mechanism both ends of the leads of the coil eX- tend from the same end thereof, this arrangement of the leads being required for convenience in making electrical connections. When the winding has proceeded nearly to the completion of the 9% turns, the slope llb (Fig. 4) of cam H3 passes by the roller [lli so that it can engage the low land I'ic, thereby permitting the lever H3 to be drawn by spring IZ against the clutch disc H5 so that the clutch will be disengaged by the time 91/2 turns are completed and the winding mechanism is in the status indicated in Fig. 19. Lever 68 (Fig. 1) is moved down to cause the blade 65 to sever the coil from the supply wire and to bend the end of the supply wire to form a hook; Plate 2i! is then elevated so that the finished coil can be removed from the form. During the winding of the coil, the turns of the coil are piled successively, one upon the other, thereby forcing the block 45 and plate i2 downwardly against the action of springs 3. When plate 2E] is raised, springs 43 cause the coil to be stripped from the form IH. The winding of the bar wire upon the coil causes the wound wire to change in characteristic from initially relatively soft to a somewhat hard or tempered condition in which it has resiliency. Therefore, when it is stripped from the winding form, the coil tends to unwind itself or fan out. The coil is then annealed to remove its temper so that its turns can easily be aligned so thatl the' coil can be placed around 'a ma'gnetilzable core having across sectional shape like the wind-l ing form 4|.

Before starting to wind the 'next coil, the windng mechanism must be moved from the status shown in Fig. 19 to the status shown in Fig. 16..' rI'his is eiiected by holding the pedal |25 in down position just long enough for the plunger H' to be retracted fromfth'e surface of 'disc H5 and the lclutch t'o be engaged and the yshaft W3v to start turning.A rihus the pedal is released so that the niotion of the disc H'E 'will be 'arrested and the machine will stop at the end of one revolu-` tion. The low land H3C (Fig. '4J Tis long enough to permit this last or 20th revolution of shaft m3 without any control by the Acam it, said cam having turned 1/2'0 revolution clockwise vfrom the position lshow'n in Fig. 4., The mechanism is then ready ffor the next winding operation.

The valve for control-ling Athe admission `of pres' sure fluid to the ends of the A"cylinder le is 'not shown. Any suitable manually operated valve may be used for this Lpurpo'se..

While theembodiment of the present invention as herein disclosed, constitutes a preferred form, it is to be understood `that oth'er forms mig-ht be adopted.

What is `claimed is as follows: i

-'1. A machine `for winding an l'oblong fcoil of flat wire comprising 'an foblong form having. parallel side surfaces and cy-lindrical Aedge portions, mechanism for causing the form to l-move length-v wise lor in a direction paraLel t'o fits-side surfaces, then to rotate about the axis of one of its edge portions, then to move lengthwise in the opposite direction and then to rotate 180 about the axis of the other of its edge portions, this cycle of movement being repeated until the required number of coil turns have been wound, members for confining the wire flatwise, one being relatively fixed and the other relatively movable, spring means urging the movable member toward the fixed member, means for limiting the initial spacing of the members to a distance substantially equal to the thickness of the' wire and for causing the wire to be maintained against the cylindrical portions of the form during rotation thereof whereby the wire is bent edgewise, the movable member moving away from the fixed member as additional turns of wire are wound and means for advancing the relatively fixed member into position adjacent the form for the coil winding operation and for retracting it after the coil is wound to permit removal of the coil from the form.

2. A machine according to claim 1 in which the relatively fixed member includes a disc rotatable on an axis parallel to the axes of the cylindrical edge portions of the form, said disc, when advanced, engaging the form and in which said means includes a smaller disc coaxial with and rotatable with the first disc and a plate engageable with one edge of the wire and extending close to the smaller disc.

3. A machine according to claim 1 in which the movable member is a block which surrounds the form and is movable therealong and which is provided with a recess for receiving a bent portion of the start end of the wire whereby the Wire is initially anchored to the block.

4. A machine according to claim l in which there is a frame movable in a direction parallel to the axes of the cylindrical portions of the form, in which the relatively xed wire-confining member includes a plate and a rotatable disc providing wire engaging surfaces in the same plane, the axis of said disc being parallel to the axes of the cylindrical edge portions of the form in which said means is a smaller disc coaxial with and rotatable with the first disc, and in which a second plate attached to the rst plate and extending close to the smaller disc is engageable with one edge of the Wire.

5. A machine according to claim 1 in which there is a frame movable in a direction parallel to the axes of the cylindrical portions of the form, in which the relatively xed wire-confining member is supported by the frame, in which there is a bracket which guides the wire toward the form and which has a die which cooperates with a punch to sever the wire and to form a hook on the start end thereof, in which the said punch is supported by the frame and is connected with means for operating it, and a machine accordi ing to claim l in which the movable member is a block which surrounds the form and is movable therealong and which is provided with a recess for receiving said hook portions of the wire.

6. A machine according to claim 1 in which the mechanism comprises an oblong gear comprising two parallel racksegments and two semi-circular gear segments having axes coaxial respectively with the axes of the cylindrical end portions of the form, said form being connected to the gear,

a driving pinion meshing with the gear, and in which there is a wire guiding means which opposes edgewise movement of the wire whereby the gear is constrained to move linearly except when its semi-circular segments are engaged by the pinion.

7. A machine according to claim 1 in which the mechanism is power driven through a clutch, and in which a clutch control is provided for effecting clutch engagement by a manual operation and clutch disengagement automatically after a predetermined number of mechanism cycles plus one-half cycle which provides for completion of a coil with the leads thereof extending in the same direction, and, following a second manually effected clutch engagement, for effecting clutch disengagement automatically after completion of the last mechanism cycle to bringthe machine into status for the next winding operation.

WAYNE HARMAN SHELEY.

REFERENCES CITED The following references are of record in the file of this patent:

UNITED STATES PATENTS Number Name Date 393,505 Green Nov. 27, 1888 678,280 Riddell July 9, 1901 919,510 Wood Apr. 27, 1909 1,005,915 Wouters Oct. 17, 1911 1,025,835 Sahlin May 7, 1912 1,878,233 Dewald Sept. 20, 1932 1,970,536 Mansur Aug. 14, 1934 FOREIGN PATENTS Number Country Date 362,450 France Apr. 6, 1906 

